PCD Cartridge Style Face Mill and End Mill Program
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1 PC Cartridge Style Face Mill and End Mill Program soft, free- non-ferrous metals (eg: 6061 aluminum, brass, and copper) graphite, carbon, green ceramics, fiber-reinforced plastics, and fiberboard low-silicon aluminum (eg: 380) high-silicon aluminum (eg: 390) metal matrix composites (eg: uralcan) K110M carbide K1410 cartridges diamond film technology KC510M coated carbide K1405 cartridges abrasiveness Features high cartridge density per cutter symmetrical body cartridge pockets forces directed to center axis open design axial adjustment thru-spindle coolant flow aluminum and steel body designs specials available Benefits higher machining feeds and speeds LH and RH with same body higher load bearing and rigidity improved chip evacuation... less chip damage improved surface finish and tool life washes chips out of cutter path... eliminates chip re- spindle load reduction for aluminum... higher speeds adds flexibility and options for using standard /cartridges M159
2 End Mills Cartridges Thread Milling Slotting ie and Mold End Mills 1. KE End Mills KE end mill KE R Insert Style B CBN PC *Special radii available upon request. 3. Hand of Cartridge R right hand L left hand End Mill Bodies (use cartridges shown above) 4. Nose Radius Wiper Flat 0 no wiper Cartridge Style 0 standard 1 long edge 7. Maximum epth of Cut standard * 3.500* 4.625* 5.750* Standard Stocked Cartridges KE-style end mills corner radius wiper flat depth of cut K1405 K1410 KER KER KER KER KER KER Vintage Cutters Widia Cutters Accessories Technical ata 1 of of adjustable shank KIPR100PC03SS , KIPR125PC03SS , KIPR150PC04SS , KIPR175PC04SS , KIPR200PC04SS ,000 overall length L head length L2 M160
3 Cutter Bodies (See cartridges on page M162.) Features cartridge cutters designed to accept RH or LH cartridges steel bodies available as specials good chip evacuation thru-spindle coolant capability Benefits better stability lower inventory/production flexibility lower hp requirements superior chip removal improved surface finishes Inch End Mills Slotting ie and Mold 1 of of adjustable KACN250PC , KACN250PC , KACN300PC , KACN300PC , KACN400PC , KACN400PC , KACN500PC , KACN500PC , KACN600PC , KACN600PC , KACN800PC , KACN800PC , KACN1000PC , KACN1000PC ,750 Metric* height L bore keyway bolt circle Accessories Vintage Cutters Widia Cutters Thread Milling 1 of of adjustable height L bore keyway bolt circle Technical ata 80, KACN80PC ,0 22,0 10,4 14, , KACN100PC ,0 32,0 14,4 12, , KACN100PC ,0 32,0 14,4 12, , KACN125PC ,0 40,0 16,4 11, , KACN125PC ,0 40,0 16,4 11, , KACN160PC ,0 40,0 16,4 10, , KACN160PC ,0 40,0 16,4 10, , KACN200PC ,0 60,0 25,4 101,6 8, , KACN200PC ,0 60,0 25,4 101,6 8,600 *Metric cutters are available as non-stock standards. Steel bodies and special cutters available upon request. See page M164 for spare parts. M161
4 Cartridges End Mills ie and Mold Slotting Thread Milling Widia Cutters Accessories Vintage Cutters 1. KC KE end mill KC face mill KC R Insert Style 3. Hand of Cartridge R right hand L left hand 5. Wiper Flat 0 no wiper Corner Radius 6. Cartridge Style 7. Maximum epth of Cut standard * 3.500* B CBN PC standard 1 long edge NOTE: Recommended cartridge for all standard purposes is a KCR cartridge. *Special radii are available. Standard Stocked Cartridges standard long edge Technical ata corner radius wiper flat depth of cut KCR KCR KCR KCR KCR KCL KCL KCL KCL K1405 K1410 M162
5 Setup Procedure for PC Cartridge-Style Milling Cutters 1. When installing new cartridges, ensure pockets are clean and free of burrs. 2. Clean bottom of cutter to ensure it is free of burrs and dirt. Cutter must sit flat on surface or setting fixture. 3. Turn adjustment hex nut down one turn with fingers. 4. Install new cartridges in body and slightly tighten with Torx wrench. 5. Set dial indicator to desired height. 6. Using 1/4" wrench, turn hex nut and adjust cartridges to within.001 from setting height lock s Tighten each cartridge to 45 in.-lbs. NOTE: Make sure s are securely tightened. 7. Using 1/4" wrench, turn hex nut to adjust the cartridge to proper setting height. To achieve the best surface finishes, all cartridges need to be within ±.0001 (0,0025 mm). 8. Check Torx s to verify that they are tight. Kennametal is not responsible for any defects caused by improper use or setting of its milling cutters. Care should be taken and exercised when handling aluminum cutter bodies. Although the outside surface is hard, it is made of aluminum and will dent or nick from improper handling. Also, all PC and grade K1405 cartridges are very brittle. Extreme caution should be taken when handling and setting diamond products. Proper handling and setting will ensure maximum cutter performance. Application ata for Grades K1405 and K1410 Maximum guidelines in the chart below must be followed per milling cutter. of cutter (inches) maximum , , , , , , , , , , ,075 Technical Support Phone: Thread Milling Slotting ie and Mold End Mills non-ferrous metals non-metallic materials workpiece material speed range (sfm) starting sfm feed rate range free-machining aluminum alloys 3,500-15,000 12, low-silicon aluminum (< 12%) 3,500-12,000 10, high-silicon aluminum (> 12%) 3,000-12,000 7, metal matrix composites 1, , free-machining copper alloys, brass, bronze, lead, and zinc 3,000-11,000 10, graphite, carbon, and unfilled plastics 2,000-8,000 4, carbon and graphite composites 2,000-7,500 3, machinable ceramics (macor) and glass 2,000-8,000 3, plastics, nylon, phenolics, and rubber 3,500-10,000 6, green ceramics 500-1,500 1, starting ipt Technical ata Accessories Vintage Cutters Widia Cutters K1410 composition: Polycrystalline diamond tip, with 25 um grain size, brazed on a standard carbide insert. application: For machining aluminum with high-silicon content; abrasive, non-ferrous metals; and fiber-reinforced plastics at very high speeds. Will produce generally good surface finishes. K1405 composition: Pure diamond material. application: Excellent for finish and semi-finish milling applications in high-silicon content aluminum and abrasive non-ferrous materials. Produces extremely good surface finishes. M163
6 Face Mill and End Mill Hardware face mills cartridge adjustment nut cartridge wrench adjustment nut End Mills ie and Mold KACN250PC03 S2137PKG x 1/3" long x 1/4" nut S2138PKG x 5/8" long TX25 Torx button head TT25 S2139PKG x 5/8" set KACN250PC06 S2137PKG " S2138PKG " TT25 S2139PKG " KACN300PC04 S2137PKG " S2138PKG " TT25 S2139PKG " KACN300PC08 S2137PKG " S2138PKG " TT25 S2139PKG " KACN400PC06 S2137PKG " S2140PKG x 3/4" long TX25 Torx button head TT25 S2141PKG x 3/4" set KACN400PC12 S2137PKG " S2140PKG " TT25 S2141PKG " KACN500PC08 S2137PKG " S2140PKG " TT25 S2141PKG " KACN500PC16 S2137PKG " S2140PKG " TT25 S2141PKG " KACN600PC08 S2137PKG " S2140PKG " TT25 S2141PKG " KACN600PC20 S2137PKG " S2140PKG " TT25 S2141PKG " KACN800PC10 S2137PKG " S2140PKG " TT25 S2141PKG " KACN800PC24 S2137PKG " S2140PKG " TT25 S2141PKG " KACN1000PC12 S2137PKG " S2140PKG " TT25 S2141PKG " KACN1000PC28 S2137PKG " S2140PKG " TT25 S2141PKG " Slotting Thread Milling end mills cartridge adjustment wrench cartridge KIPR100PC03SS3 S2142PKG 6-32 x 1/2" long set KW078 S2143PKG 6-32 x.36" long T15 Torx TT15 KIPR125PC03SS4 S2142PKG " KW078 S2143PKG " TT15 KIPR150PC04SS4 S2144PKG 8-32 x 1/2" long set KW078 S2143PKG " TT15 KIPR175PC04SS5 S2145PKG x 1/2" long set KW093 S2143PKG " TT15 KIPR200PC04SS5 S2145PKG " KW093 S2143PKG " TT15 wrench Technical ata Accessories Vintage Cutters Widia Cutters presenting... Kennametal s PC iamond Cutter Program Engineered specifically to deliver ultimate performance in non-ferrous milling applications! Excellent surface finishes 2" thru 10" s Cutters accept right- or left-hand cartridges All pockets are axially adjustable Capable of high metal removal rates Call 800/ M164
7 High-Performance Milling and Cutters RNG-T ISO inch dimensions mm inch S mm KY2100 grades KY1540 RPG RNG45T0420 RNG120700T /2 12,70 5/16 7,94 ISO inch dimensions mm inch S mm grades KY2100 KY1540 Guidelines for Cutting Speed and Feed by Material Groups for High-Performance material grade High-Performance End Mill 0 /90 Hi-Temp Alloys KIPR-RP Clamp-on Insert Integral Shank For use on both high-temperature alloys and stainless steels. feed range speed range ipt mm/tooth sfm m/min PH stainless steels KY ,05-0, , 15-5, and 17-4 KY ,08-0, < HB ( 48 HRC) d 300 series austenitic stainless steel 302,303,304,316,321,347, and 329 KY ,05-0, d HB ( 28 HRC) iron-base, heat-resistant alloys A286, iscaloy, Incoloy KY ,05-0, d KY ,05-0, d HB ( 34 HRC) cobalt-base, heat-resistant alloys KY ,05-0, d Haynes 21/25/188, Stellite HB ( 45 HRC) KY ,05-0, d nickel-base, heat-resistant alloys Inconel 601/617/625/718/x-750/901, Nimonic 80A, KY ,05-0, d Waspaloy, Rene 95, Hastaloy C, Udimet 700 KY ,05-0, d HB ( 48 HRC) titanium and titanium alloys HB ( 48 HRC) NOT RECOMMENE Use calculated vs actual chip corrections chart on page M166 when determining actual chip load. RPG43 RPGN /2 12,70 3/16 4,76 wet or dry Accessories Vintage Cutters Widia Cutters Thread Milling Slotting ie and Mold End Mills Technical ata 1 ANSI no. of shank KIPR125RP KCI3 S1997PKG < KIPR125RP KCI3 S1997PKG < KIPR125RP KCI3 S1997PKG KIPR150RP KCI3 S1997PKG KIPR150RP KCI3 S1997PKG KIPR150RP KCI3 S1997PKG overall length L head length L2 maximum M165
8 High-Performance Face Mill 0 /90 Hi-Temp Alloys KNR-RN Clamp-On Insert Shell Mill These cutters are your best choice for milling high-temp alloys. End Mills ie and Mold Slotting Vintage Cutters Accessories Technical ata Widia Cutters Thread Milling 1 ANSI total no. of height L bore KNR200RN40C KCI KNR250RN40C KCI KNR300RN40C KCI KNR400RN40C KCI KSSR-RP Clamp-On Insert Shell Mill keyway K1 These cutters are your best choice for milling PH stainless and 300 series stainless steel. 1 ANSI total no. of height L bore keyway K KSSR200RP430C KCI3 S1997PKG KSSR200RP430F KCI3 S1997PKG KSSR250RP430C KCI3 S1997PKG KSSR300RP430C KCI3 S1997PKG KSSR400RP430C KCI3 S1997PKG Calculated vs. Actual Chip Correction Chart Insert radius =.25" Correct IPT is to be used to calculate the feed (IPM) M166 axial depth of cut desired actual chip load corrected IPT corrected IPT corrected IPT corrected IPT
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